Continuous casting machine having a variable mold length and adapted for casting in a variety of sizes at high speed

ABSTRACT

A continuous casting machine comprising means for holding a body of molten metal, a feed nozzle connected to said means, a mold assembly including a mold rotatable about the feed nozzle, means for moving the mold assembly back and forth upon the feed nozzle, and means for forcing a lubricant through the nozzle to lubricate casting. Means for applying a cooling medium to the mold and means for withdrawing the casting are additionally included.

United States Patent Inventors Appl. No. Filed Patented Assignee CONTINUOUS CASTING MACHINE HAVING A VARIABLE MOLD LENGTH AND ADAP'I'ED FOR CASTING IN A VARIETY OF SIZES AT HIGH SPEED 3,040,396 6/1962 Hudson 164/73 3,390,716 7/1968 Rossing.... 164/281 3,439,730 4/1969 Moritz 164/82 1,088,171 2/1914 PBhl'SOn 164/282x 3,349,837 10/1967 Brondykeetal 164/282x 1,139,888 5/1915 Mellen .1 l64/279X 2,316,144 4/1943 Coxe.... 164/279x 2,799,068 7/1957 Zeigler l64/89 2,871,529 2/1959 Kilpatrick 164/283 3,556,197 1/1971 Foye 164/268 FOREIGN PATENTS 588,618 5/1947 GreatBritain 164/282 59 Claims, 13 Drawing Pb. Primary Examiner-R. Spencer Annear Us CI 164,268 Auorneys- Henry W. Cummings, Richard S. Strickler, Robert 64/283, H. Bachman, Donald R. Motsko and Thomas P. y Int. Cl. ..B22dll/l0,

822d 1 ABSTRACT A contin 0 ast' ch'n c 164/73 82 u c mg ma I e ompnsmg 268 273 282 means for holdmg a body of molten metal, a feed nozzle con- 8 nected to said means, a mold assembly including a mold I I I rotatable about the feed nozzle, means for moving the mold U SS m assembly back and forth upon the feed nozzle, and means for NIT forcing a lubricant through the nozzle to lubricate casting. Zelgler CI al Means for a cooling medium to the mold and means 3,022,552 2/1962 Tessmann l64/258 for withdrawing the casting are additionally included.

W I; Z A 4 3 mi 40 I u F:

I ll A} 33 .9 ll: ;:7 1 l fl 5 1 7? I03 0 g 4 J a A .t I I z I /05 i C i g N v 1 ,0 J: I J 54 PATENTED mm 0 I971 SHEET 1 [IF 8 N -QDN I N VEN'IT. )RAS, JAMfS E. DORE WILL MM 0. .STAUFFER 4"". mix/LT) ATTORNEY PATENTEU AUGIOB?! 3.598173 JAMES E. DORE W/AL MM 0 5 TAUFFEQ ATI JRNI. Y

INVENTORS.

PATENTEU AUBI ms?! 3,598,173

SHEET u 0F 8 INVEN'IORS JAMES E. DORE .WIL LIAM 0Y 5M UFFER A ORNEY PATENTED mm 0 [an SHEET 5 0F 8 PATENTED M1910 I97! SHEET 6 OF 8 INVENTORY JAMES E DOPE W/LL/AM 0.5TAUFFER ATTORNEY PATENIED AUG 0 l9?! SHEET 7 UF 8 INVENTORS;

JAMES E DORE W/LL/AMO. STAUFFER l 'l ll ATTORP EY PATENTED Aum 01971 SHEET 8 OF 8 RE v m m a QQQ INVENTORS. JAMES E. DORE W/ZL /AM 0. STAUFFE/P BY Wu) r L w. w" Ll ATTORNEY CONTINUOUS CASTING MACHINE HAVING A VARIABLE MOLD LENGTH AND ADAPTED FOR CASTING IN A VARIETY OF SIZES AT HIGH SPEED Most of the present day wrought aluminum alloy products (sheet, extrusions, wire and forgings) are made from process billet produced by vertical direct chill-casting operations. However, considerable amounts of scrap are generated in the casting of alloy billet due to gross surface defects that must be removed by scalping. Also, it is difficult to cast small cross section alloy billet in the DC operation. Production rates are low and conversion costs are high.

Billet of small cross section can be made continuously on Properzi casting machines, as described, for example, in US. Pat. No. 2,7l0,433. However, at the present time, product availability from Properzi machines is limited and high quality product cannot be made in alloys such as 5356, 4043, 6061, and other industrial wire alloys.

A modified Tessman casting process, as described, for example, in US. Pat. No. 2,837,791, can be used to continuously cast 2%-inch diameter rod in Electrical Conductive grade and 5005 alloys. However, because of heat transfer considerations inherent in the design and the action of the reciprocating mold, highly alloyed product cannot be cast with this process.

Other horizontal casting processes are limited because of less than desirable internal or surface quality of the billet. Billet of medium alloy content can be cast with the Ugine process, as described, for example in REVUE DE LALU- MINUM, Vol. 34 (1957) No. 244, p. 624-627, but the casting rates are low. The cast billet must be large in cross section to reduce scrap losses during scalping and the cost of the finished product is about equal to that of the vertical DC casting process.

Furthermore, for a given alloy, a given amount of superheat (casting temperature), a given casting speed, and a given amount of cooling fluid applied to the mold, there is a given mold length that will produce billet of optimum surface quality and smoothness. However, this ideal length is different if any, or all, ofthese variables are changed. Thus, it is important to be able to vary the mold length to adjust to these varied conditions and obtain optimum surface quality and smoothness.

Furthermore, the mold length is preferably different during startup than duringthe rest of the casting operation. With the mold arrangement of the present invention, after startup has taken place, the mold assembly can be moved to obtain the desired mold length for the given alloy, superheat and cooling condition while casting continues to obtain optimum surface quality.

It is an object of the present invention to provide a casting method and apparatus whereby a variety of aluminum alloy systems may be continually cast.

It is another object of the present invention to cast a variety of alloy systems in a variety of sizes.

It is another object of the present invention to provide a method and apparatus for casting a variety of alloy systems in a variety of sizes at high casting speed.

It is another object of the present invention to produce continuous castings having such a sufficiently fine quality of surface that no scalping or other surface treatment is necessary prior to hot working the casting.

It is still another object of the present invention to produce a continuous casting having a sound internal metallurgical structure.

It is still another object of the present invention to provide an apparatus wherein the mold length may be varied for dif ferent alloys and may be varied while the casting machine is being operated.

It is still another object of the present invention to provide a method and apparatus at a cost as low as or lower than the methods and apparatus presently available.

It is still another object of the present invention to provide a method and apparatus which will insure that the cast bar will be straight.

Other objects and advantages will become apparent from the following description and drawings, in which: 1

FIG. 1 is a sectional view of a portion of the continuous casting apparatus of the present invention;

FIG. 2 is a sectional view of a portion of the feed nozzle in cooperation with the mold of the present invention;

FIG. 3 is a sectional view along the lines 3-3 in FIG. 2;

FIG. 4 is another embodimentof the feed nozzle in cooperation with the mold of the present invention. I

FIG. 5 is a schematic view of a method of affixing fibers to the feed nozzle shell in FIG. 4;

FIG. 6 is a partial top view illustrating a portion of the apparatus shown in FIG. 1;

FIG. 7 is a perspective view of one mold structure according to the present invention;

FIG. 8 is a sectional view along the lines 8-8 in FIG. 7;

FIG. 9 is a side view of the ingot withdrawal mechanism and drive mechanism of the present invention.

FIG. 10 is a sectional view along the lines l0-l0 in FIG. 9;

FIG. 11 is a sectional view illustrating modifications of the present invention;

FIG. 12 is a sectional view along lines 12-12 in FIG. 11; and

FIG. 13 is a schematic view of the conduit system used to regulate the amount of oil applied to lubricate the casting.

The casting machine of the present invention consists of the following basic parts.

As shown in FIG. 1, there is provided a metal holding unit 10, such as, for instance, a feed box having an insulating lining 12 made of, for example, Marinite. The feed nozzle insert 412 is placed in abutment with the holding unit 10, separated therefrom by gaskets 10a and 10b. The feed nozzle is supported on an adjustable V-block 30 mounted on the bed ofthe machine. The V-hlock has an upper portion 31 and a lower portion 32 with the upper and lower portions being held together'in a tight fit around the feed nozzle by means of bolts The mold assembly 50 consists ofa bearing block 51 which may be of one or two pieces, but a two-piece design is preferred because of ease of assembly and disassembly, a drive sprocket 58, and a mold 20. Bolts 52 hold these parts in engagement. As shown in F IG. 6, rotational power is applied to a shaft S and to belt 59 to drive the mold assembly. This entire assembly is rotated about the feed nozzle 40 by means of the drive sprocket 58. No special lubrication is required for this rotation. It is only necessary to apply a small amount of oil by hand to the feed nozzle 40 prior to assembling the mold assembly 50. Alternatively, if desired, a conventional lubrication system can be provided to lubricate the rotating mold assembly, either separate from, or as a part of, the mold lubrication system, by providing appropriate passageways in feed nozzle 40.

As shown in FIG. 6, the entire mold assembly is movable with respect to the feed nozzle by a lever 53 held in place by a nut 55. Cam followers 56 are provided which will rotate if the mold assembly is moved forward or backward while the mold assembly is rotating. The mold may thus be held at a given distance from the V-block 30. The effective mold length M decreases as the mold assembly is drawn nearer to the V-block 30-31 and is lengthened as the mold assembly is moved further from the V-block.

The oil to be introduced into the mold ofthe horizontal continuous casting machine of the present invention is fed from suitable reservoirs 1000 and 1001.. Compressed air is supplied through an air supply line 1003 having a pressure reducing valve 1004 therein. The air supply line which is fitted with a pressure gage 1007 divides into two lines 1005 and 1006 which lead to the reservoirs. Sight glasses 1008 and 1009 are provided. so that the oil level in reservoirs can be observed. Each sight glass is also in communication with bleed valves 1010 and 1011 so that trapped air can be bled from the system. Oil can be drained from either oil reservoir through valves 1018, 1019, 1020 and 1021. It will be apparent that either oil reservoir 1000 or 1001 can be shut down and refilled and the other utilized during the course of casting, thus assuring continuous operation. The oil level can be read from either the sight glasses 1008 or 1009. The pressure on the reservoirs can be varied through the use of reducing valve 1004. In order to shut off the oil reservoirs, either the valves 1018 or 1020, as desired, are used to shut off respectively the reservoirs 1000 and 1001. Reducing valve 1004 controls the pressure applied to the oil reservoirs, which, in turn, controls the amount of oil delivered to the feed tube 14 or the feed nozzle 40.

It will be apparent to those skilled in the art that a desired volume of oil can be delivered to the feed tube and subsequently to the mold. By closing the valve 1018 or 1021, depending on which reservoir is in use, the actual flow rate of oil to the feed tube can be measured since the sight glasses are calibrated in measured volume units.

In FIG. 2, the feed nozzle 40 is shown in detail, cooperation with mold member 20. The oil to be introduced into the mold of the horizontal continuous casting machine of the present invention is housed in a suitable oil supply system previously described which is connected through appropriate couplings to the feed tube 14 shown in FIG. 1 and then into a capillary 402 made of any convenient material, such as stainless steel.

The capillary is placed in a longitudinal groove 401 in the feed nozzle shell 400 (FIG. 3) made of cast iron, such as meehanite. After insertion of the capillary, the remaining space in the groove is filled with molten solder, of a composition well known to those skilled in the art, for example, silver solder. Upon solidification, the solder 404 will hold the capillary in place. A a plurality of such capillaries may be provided, if desired. Two are shown in FIG. 1. Between the feed nozzle shell 400 and the mold 20, an O-ring seal 405 is placed in O- ring groove 406, so that the oil does not simply take the path of least resistance and run back out through the passageway 403 between the mold 20 and the feed nozzle shell 400 and out through the bearing block 50 to the atmosphere. The feed nozzle shell 400 has a step 408. At the end of this step is placed a layer of felt, cotton yarn, or other fibrous material 409, such as Teflon felt. The layer 409 together with the O- ring 405, step 408, and the mold 20 define a circular hollow chamber 407 which serves as an oil reservoir.

A very important part of this assembly is the feed nozzle tip 410. The tip must have the following characteristics:

1. It must be made of refractory material which will withstand the temperatures of all molten aluminum alloys,

2. It must be nonmelting to molten aluminum,

3. It must have a relatively low bulk heat capacity,

4. It must have relatively low thermal conductivity,

5. It must be resistant to thermal shock, and

6. It must be machinable to close dimensional tolerances.

An example of one suitable material is Marinite, which is a mixture of asbestos fiber bonded with a cementing agent.

The tip 410 is connected to the feed nozzle shell 400 by suitable means such as threads 411 so as to abut the feed nozzle insert 412 and the beveled end of the feed nozzle shell 400. Preferably, one or more gaskets 413, 414 are provided between the tip 410 and nozzle insert 412.

The tip 410 is designed so as to surround the feed nozzle shell 400 because it has been found that if the shell is exposed to the molten metal, the molten metal will solidify thereon, resulting in surface defects, such as tearing of the surface of the casting.

The clearance between the tip 410 and the mold 20 must be such that the lubricant will pass from the fibrous material 409 between the mold and the'nozzle and lubricate the mold, but small enough to prevent molten metal from entering this passageway. The thickness may vary from one-half to five thousandths of an inch per side. Moreover, it has been found that the necessary clearance depends upon the head H in the feed box shown in FIG. 1. For example, with a metal head of 15 inches and a 0.005 inch gap per side, tearing was observed, but such tearing was not observed with the same gap and a metal head of 12 inches.

The fibrous material 409 is not always of uniform density throughout the entire circumference. Therefore, to the extent that there is a lack of uniformity in the fibrous material, there is a tendency for the oil to be unevenly distributed about the inside of a mold 20. This results in some material solidifying where there is too little oil, and in vapor formation where there is too much oil.

In order to overcome this deficiency, the mold is rotated, as previously mentioned. In this fashion, a given portion of the fibrous material is present only instantaneously at any given portion of the mold. This results in an oil distribution which is very uniform throughout the length and circumference of the mold.

Another embodiment of the feed nozzle 40 is shown in FIG. 4. In this embodiment, the feed nozzle shell 400 again has a capillary 402 contained in a groove therein which also may be held in place by solder 404 as was the case in FIGS. 3 and 4. There is also an O-ring 405 placed in O-ring groove 406 in engagement with he mold 20. The liquid reservoir 407 is defined by the step 408, the mold 20, the O-ring seal 405, and a flock F described below.

However, in this embodiment, the feed nozzle shell 400 is shaped differently. The tip thereof 409 is reduced in cross section to within the range of from about 0.002 inch. to 0.010 inch, and is preferably about 0.005 inch thick.

The flock F is made of short, chopped fibers of a material such as rayon or nylon, which are applied to the surface of the feed nozzle shell and are held thereon by a cement, for instance, epoxy cement. The flock fibers are approximately one sixty-fourth inch to one-sixteenth inch long, and are applied perpendicularly to the surface of the feed nozzle shell as densely as possible.

This application, for instance, can be carried out according to the schematic diagram shown in FIG. 5 wherein a plurality of such fibers F are placed upon the surface S. The feed nozzle shell member M is fixed within the chamber C above the fibers F. A high voltage source V is connected to both the member M and the surface S, which may be of the order of 20,000 volts. This results in the fibers F being deposited upon the feed nozzle shell member perpendicularly thereto. Prior to insertion of the member M, the surface thereof has been coated with an appropriate cement, such as an epoxy cement, so that the fibers become affixed in perpendicular relationship to the surface of the feed nozzle shell member and are packed as densely as possible.

Other methods perhaps may be devised by those skilled in the art for affixing the fibers upon the feed nozzle shell, but this is the preferred method.

Thus, when the Marinite tip 410 is affixed to feed nozzle shell 400, for instance, by means of threads 411 abutting the feed nozzle insert 412, the Marininte member covers all of the meehanite except for the tip 409. However, the flock F insures a steady flow of oil over the tip 409 and the tip will not come in contact with molten metal if the above tip thickness of 0.002 to 0.010 inch is maintained. Again, it is preferred to utilize one or more gaskets 413 and 414 between the Marininte tip 410 and the insert.

FIG. 1 illustrates one embodiment of the mold and cooling water application structure.

In this embodiment, cooling water is introduced into the chamber 601 ofmold spray box 607 by means of conventional couplings 602 known to those skilled in the art. From the spray box, the cooling water passes through a circumferential baffle in the spray box containing a series of holes 603 into a second chamber 604. A plate 605 is affixed to mold spray box 607 by means of fasteners 606. However, it is to be noted that there is a step 608 on the plate 605 resulting in clearance of from 13 to 50 thousandths of an inch, preferably 15 to 25 thousandths, between the plate and the lower portion of the spray box 607. Thus, the cooling water passes in a continuous sheet from chamber 604 between the plate 605 and the spray box 607 contacts first the mold plate 103 and then the mold 20. It then follows the mold contour and exits from the billet surface at 105 at an angle of from 3 to 20 to the surface of the casting. An angle of 3 to between the cooling water and the casting at the point of contact is preferred for most applications.

It can also be seen from FIG. 1 that the mold plate 103 contacts cam followers 124 which are journaled on the pins 121. Nuts 120 hold the pins firmly in place within the fixed support 125, which is appropriately affixed to the mold spray box in a conventional manner such as by fasteners or by welding. Thus, the mold plate and the cam followers rotate and the mold spray box remains stationary.

As to the mold itself, the mold shown in FIG. 6 is shown in enlarged views in FIGS. 7 and 8. The mold may be made of any of the following materials: deoxidized copper, aluminum, copper with a graphite insert, or deoxidized copper containing 1.3 percent chromium. As shown in FIG. 7, the mold 20 comprises a continuous concave surface 201 or curved surface which may take the form of the arc of a circle, a segment of a parabola or a segment of an hyperbola. This provides maximum heat removal from the mold by minimizing the thickness of the stagnant bounding layer of coolant in contact with the surfaces of the mold and delivers coolant to bar surface at the proper angle, as previously specified. As shown in FIG. 8, a plurality of helical grooves 202 are provided which are cut 0.001 to 0.003 inches deep into the internal surface of the mold for a considerable distance, such as l to 2 inches from the discharge end. The grooves may be made using a 30 knurl with a 33 pitch right-hand diameter knurling wheel. The direction of the helix is in the direction of mold rotation. Thus, when the mold is rotated, the grooves pump oil down the length of the mold so that a thin film of oil separates the casting from the mold. Proper and uniform distribution of oil over the entire length of the mold is essential in order to cast bar of excellent surface quality.

As shown in FIG. 1, after the casting emerges from the mold, wiping and cooling arrangements are provided within a splash chamber. Within this chamber, there is provided a mechanical wiper 710. This wiper includes one or more gaskets 711. I5the case of ZA-inch diameter cast bar, 2-inch size gaskets are used to provide effective wiping action and good contact with the casting 3. These gaskets are mounted in a holder 712 which, in turn, is held in the wiper housing 713 with conventional fasteners such as nut-and-bolt arrangement 714.

Adjacent the mechanical wiper 710 is an air wiper 720. The air wiper 720 comprises a header section 721 which surrounds the casting circumferentially and a plurality of nozzles 720 through which the air passes at an angle of 30 to 60, preferably 45, with respect to a plane passing through the header. The size of the nozzles may be a slot orifice of 0.045 inches. The number of orifices 722 may vary, for example, from 3 to 20, but it is preferred to have from 6 to 8 orifices. An air pressure of, for example 100 p.s.i. is applied through a suitable conduit 723 from a pump, not shown. The purposes of the air wiper is to remove any water from the surface of the bar that gets by the mechanical wipers.

Additional cooling may be provided if desired and, in fact, is necessary in the casting of certain stress sensitive alloys. Such additional cooling may be provided at a secondary cooling station 730. The secondary cooling station is simple in construction. There is provided a housing or header 731 into which a cooling medium, for example, water, is introduced through conduit 732. A plurality of drilled holes 733 are provided which are quite close to the casting. The angle between the surface of the casting and the drilled holes 733 may be from to 45, preferably 30. The number of such holes should be between 15 and 45, preferably to 30. The diameter of such holes must be from one-sixteenth inch to live thirty-seconds inch, for example, 3/32-inch diameter may be used. The water may be applied at a rate of 10 to 100 gallons per minute, de-

pending on casting speed and the alloy and size of bar being cast. Upon leaving the secondary cooling station 730, the secondary cooling water may be removed with additional wipers such as shown at 740, held in place with support 741 and fasteners 742. If desired, an additional air wiper such as shown at 720 may also be provided. Also, if desired, the mechanical wipers and/or air wiper may be replaced with a water wiper which directs a continuous sheet of water up the bar in a direction opposite to the direction of bar travel. The sheet of water issuing from the water wiper should make an angle of between 15 and 45 with the bar surface. The flow rate of water issuing from the water wiper is determined by the amount of water being applied to the surface of the bar by the secondary cooling station. Water flow from the wiper is adjusted so that no water exits the splash chamber or encloses down the bar.

Then, as shown in FIGS. 9 and 10, the casting passes to an ingot withdrawal mechanism 900.

The ingot withdrawal mechanism 900 is driven from a motor 910, which, by means of belt 911 and gear reducers 912, 913, and 914, drives a sprocket 915. In the gear box 914, the power is divided by known gearing, part going to the sprocket 915 and part continuing to another gear box 917. The sprocket 915 drives a chain 916 which, in turn, drives wheel 920. In the gear boxes 917 and 918, the rotational rate is further reduced and drives shaft S. As will be apparent from FIG. 6, the shaft S transmits the power to belt 59 which rotates the mold assembly. While a single motor has been illustrated as driving both the withdrawal mechanism and the motor rotation mechanism, it will be obvious to one skilled in the art that separate motors and separate gear trains could be provided. The motors and gear trains are conventional in the art and are not, in themselves, novel, except insofar as they are combined with the casting method and apparatus of the present invention.

The wheel 920, driven by the chain 916, contains a plurality of grooves 921 into which the wheels 931 fit.

The chain 901 is made up ofa plurality of feet 930. Tl-Ie feet 930 comprise a V-member 933 upon which the casting 3 rides. The V-member has flat faces which converge in an inverted apex 935. The V-member has a groove 936 in its bottom surface. A guide bar 940 is provided and the V-members ride along the guide bar 940 as they carry the casting 3. The wheels 93] are affixed to the V-member by means of lugs 937 which are welded onto the V-members. Of course, other types of fastening could be utilized, if desired. The chain of feet also rides on an idler wheel 922 prior to engaging the casting.

The withdrawal mechanism also includes a device 950 to hold the casting in place and in engagement with the feet 930. This device comprises wheels 951 and 952 having axles 953 and 954. An air cylinder, not shown, exerts a force on drive member 956 which exerts this force midway between the wheels on a bar 955 which distributes the force equally between the wheels. The amount of pneumatic pressure to be applied can be varied by varying the amount of pressure applied to the air cylinder.

After the casting leaves the withdrawal mechanism. it may be placed upon a series of roller bars 960 for support and then to a cutting device or saw of conventional construction, not shown.

Another embodiment of the invention is shown in FIG. 11. Much of the embodiment shown in FIG. 10 is essentially the same as that shown in FIG. 1. I

As was previously described, molten metal to be cast is held in a feed box 10 having appropriate insulating lining 12, for example, made of Marinite. Additional molten metal is added continuously through a transfer trough 1 in communication with a furnace or large reservoir of molten alloy.

There is also provided a V-block 30 having an upper and lower portion 31 and 32, the two sections being held in engagement by means of bolts 33. Feed tube 14 is provided for the introduction of lubricating oil into capillary 402. A mold sprocket 58 and belt 59 are provided to rotate the mold assembly 50 which is held together by means of bolts 52. The mold assembly 50 can be moved back and forth on the feed nozzle 40 and tip 410 by means ofa lever, such as 53 shown in FIG. 6 to vary the mold length M. Cam followers 56 avoid friction during movement of the assembly back and forth while the assembly is rotating.

Cooling water is supplied to the mold 20 by introduction of the cooling water into spray box 111. In this embodiment, the spray box directs the cooling medium in a direction parallel to the movement of the casting but in an opposite direction to the casting movement. The mold surface 21 then turns the cooling fluid and directs it onto the casting 3 at an angle from 3 to 20 to the surface of the casting, preferably 3 to 10.

in FIG. 11, the cooling water is shown introduced in a direction parallel but opposite to the direction of travel of the mold. In FIG. 1, the cooling water in introduced perpendicular to the direction of travel of the mold. Thus, it is apparent that the cooling water may be introduced at any convenient angle with respect to the movement of the casting, so long as the mold contour is such as to direct the cooling water to contact the castings as it emerges from the mold at an angle from 3 to to the surface of the casting, preferably 3 to 10.

If desired, additional cooling of the ingot may be provided through the use of header 141 and superquench nozzles 142 (US. Pat. No. 3,323,577) which are placed within cooling chamber 13. At the entrance to the cooling chamber, means for wiping the casting may be provided at 15, for instance, rubber wipers 151 may be provided affixed into holders 152 by conventional fasteners. An additional rubber wiper 16 may be provided as the casting exits from chamber 13.

The ingot withdrawal mechanism 60 comprises a plurality of feet 61 connected by a plurality of links 631. As shown in FIG. 12, a V-member 63 has two inclining faces which support the casting. The V-member is welded to base member 64. The bolts 68 hold the base 64 in engagement with the links 631. A roller bearing 69 is free to rotate about the pins 632 and per mit the links to bend as they pass around idler wheel 62.

The drive mechanism for the withdrawal mechanism is similar to that shown in FIG. 9. The drive sprocket which imparts the motion to the chain 61 may be of the simple bicycle sprocket type (not shown) with teeth thereon which engage the feet 61. This type of sprocket-and-chain arrangement is conventional and forms no part of the present invention, ex cept insofar as it is in combination with the feet 61 and other casting apparatus ofthe present invention.

Finally, ultrasonic testing equipment, shown schematically at 980, known in the art, may be used in testing the soundness of the casting after the casting has been removed from the mold, coolant removal section, and secondary cooling removal section. Such testing of the soundness of metallurgical products, such as bar stock, is known in the art and forms no part of the present invention, except insofar as it is combined with the casting process and apparatus of the present invention.

It is to be understood that the invention is not limited to the illustrations described and shown herein which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modifications of form, size, arrangement of parts and detail of operation, but rather is intended to encompass all such modifications which are within the spirit and scope of the invention as set forth in the appended claims.

What we claim is:

l. A horizontal casting feed nozzle adapted to be used in conjunction with a horizontal casting mold utilized in making a continuous casting comprising:

a nozzle body having a step therein;

a capillary communicating with said step for carrying a lubricant thereto;

a tip attached to the end portion of said nozzle body. said tip hciug uouwctting to molten aluminum;

menus for introducing a lubricant to llow through said capillary; and

means for communicating with said step for regulating the amount of lubricant which passes over said tip to lubricate the casting. 2. A feed nozzle according to claim 1 in which the means for regulating the flow of lubricant over said tip is a layer of fibrous material.

3. A feed nozzle according to claim 2 in which the fibrous material is selected from the group consisting of felt, cotton yarn, Teflon, rayon and nylon.

4. A feed nozzle according to claim 2 in which the fibrous material is a plurality of short, chopped fibers and said fibers being substantially perpendicular to the surface of said nozzle body.

5. A feed nozzle according to claim 1 in which said tip completely covers the end portion of said nozzle body.

6. A feed nozzle according to claim 1 in which means for sealing said feed nozzle with respect to said mold are provided which insure that said lubricant will pass over said tip.

7. A feed nozzle according to claim 1 in which said capillary lies within said nozzle body.

8. A casting mold utilized in making a continuous casting comprising:

a member having a concave outer surface and having an opening of constant diameter therethrough defining an inner surface; said member further having a plurality of helical grooves extending along the inner surface thereof for passage of a lubricant through said grooves to lubricate said casting.

9. A mold according to claim 8 which is made ofa material selected from the group consisting of deoxidized copper, aluminum and aluminum alloys, copper having a graphite insert, and deoxidized copper containing up to 1.3 percent chromium.

10. A mold according to claim 9 which is made of deoxidized copper containing up to 1.3 percent chromium.

11. A mold according to claim 10 in which the chromium content is about 0.8 percent.

12. A mold according to claim 8 in which the grooves are from 0.001 to 0.003 inch deep.

13. A mold according to claim 8 in which the concave mold surface is parabolic.

14. An apparatus utilized in making a continuous casting comprising:

A. a mold assembly, including a mold wherein at least a portion of the outer surface of said mold is concave and having an opening of constant diameter therethrough defining an inner surface, wherein said concave surface is contiguous with the end of said opening from which said casting emerges and wherein the diameter of said concave surface increases from said end portion, and a plurality of helical grooves extending along the inner surface of said mold for passage ofa lubricant to lubricate said casting; a feed nozzle communicating with said mold, said mold being rotatable about said feed nozzle, and

B. means for applying a first cooling medium to the outer surface of said mold and the emergent portion of said casting.

15. An apparatus according to claim 14 in which the means for applying a cooling medium to said mold is fixed.

16. An apparatus according to claim 14 in which the means for applying a cooling medium comprises a spray box having a circumferential baffle, said baffle having a plurality of openings therein.

17. An apparatus according to claim 14 in which said spray box is provided with a plate affixed to said spray box, said plate being so shaped as to regulate the direction and pressure of applied cooling medium.

18. An apparatus according to claim 17 in which said plate has a portion of reduced thickness which regulates said cooling medium.

19. An apparatus according to claim 17 in which said spray box contains a circumferential header in addition to said baffie.

20. An apparatus according to claim 17 in which said mold assembly includes a rotatable mold ring affixed to said mold and in which said mold ring engages a cam follower which is affixed to said spray box. I

21. A casting machine utilized in making a continuous casting comprising:

means for holding a body of molten metal which defines a head of molten metal at least in excess of the diameter of said mold;

a feed nozzle connected to the means for holding said body of molten metal;

means for supporting said feed nozzle, said feed nozzle having a nozzle body having a step therein, a capillary communicating with said step for carrying a lubricant, a tip attached to the end portion of said nozzle body, means for introducing a lubricant to flow through said capillary, and means communicating with said step for regulating the amount of lubricant which passes over said tip to lubricate the casting;

a mold assembly rotatable about said feed nozzle said mold assembly including a mold for horizontal casting; means for moving the mold assembly back and forth upon said feed nozzle;

means for forcing said lubricant through said feed nozzle to lubricate said casting formed within said mold; means for applying a cooling medium to said mold; means for withdrawing said casting as it emerges from said mold and for supporting said casting while it solidifies.

22. An apparatus according to claim 21 including means for removing the cooling medium from said casting.

23. An apparatus according to claim 22 in which means are provided for applying additional cooling to he casting after said casting emerges from said mold.

24. An apparatus according to claim 22 in which said means for withdrawing includes means for applying a force to the upper surface of said casting to hold said casting in engagement with said withdrawal mechanism.

25. An apparatus according to claim 21 in which a part of the same rotational energy used to operate said means for withdrawing a casting is used to rotate the mold assembly.

26. An apparatus utilized in making a continuous casting comprising:

A. a mold having a concave outer surface and having an opening of constant diameter therethrough defining an inner surface said mold further having a plurality of helical grooves extending along the inner surface thereof for passage of a lubricant through said grooves to lubricate said casting; and

B. A withdrawal mechanism for withdrawing said casting comprising: an endless chain made up of a plurality of feet, each of said feet having a carrying member having a concave surface upon which said casting is carried, said carrying member having means for moving along the base having a flat surface; and means for moving said endless chain into engagement with said casting and out of engagement with said casting after said casting has been moved away from said casting mold.

27. An apparatus according to claim 26 including means associated with the base for guiding said chain as it moves along said base.

28. An apparatus according to claim 26 in which said means for moving along said base are wheels.

29. An apparatus according to claim 26 in which means are provided for exerting a force on the top of said casting to hold said casting in engagement with said carrier member.

30. An apparatus according to claim 29 in which means are provided for varying the pressure applied to the casting.

31. An apparatus according to claim 29 in which said force is applied to said casting through the use of a pneumatic cylinder or hydraulic cylinder.

32. An apparatus according to claim 26 in which the means for urging said endless chain into engagement with said casting comprises at least one drive sprocket wheel.

33. An apparatus according to claim 32 in which an idler wheel is provided which said endless chain engages in its travel.

34. An apparatus according to claim 32 in which said drive wheel has openings therein and wherein said endless chain engages said openings as said endless chain travels about said wheel.

35. An apparatus according to claim 32 in which the source of power used for moving said endless chain is a motor.

36. An apparatus according to claim 35 in which a part of the rotational energy obtained from said motor is used to rotate the mold.

37. An apparatus according to claim 35 in which at least a part of the rotational energy obtained from said motor is used to drive a sprocket wheel which drives said endless chain.

38. An apparatus according to claim 26 in which means for testing the soundness of said casting is provided after said casting is moved away from the mold.

39. An apparatus according to claim 38 in which the testing means used is ultrasonic testing.

40. A mold according to claim 8 in which a mold coolant exits from said externally concave outer surface at an angle of 3 to 20 to the surface of the casting.

41. A mold according to claim 40 in which the angle is 3 to 10.

42. An apparatus according to claim 21 wherein at least a portion of the outer surface of said mold is concave and having an opening of constant diameter therethrough, wherein said concave surface is contiguous with the end of said opening from which said casting emerges and wherein the diameter of said concave surface increases from said end portion, and wherein said mold has a plurality of helical grooves extending along the inner surface thereof for passage of a lubricant through said grooves to lubricate said casting and further wherein said cooling medium exits from said concave surface at an angle of from 3 to 20 to the surface of said casting.

43. An apparatus according to claim 42 in which the angle is 3 to 10 to the surface of the casting.

44. A mold assembly for a continuous casting machine for making a continuous casting comprising:

A. a mold having a concave outer surface and having an opening of constant diameter therethrough defining an inner surface; said mold further having a plurality of helical grooves extending along the inner surface thereof for passage of lubricant through said grooves to lubricate said casting,

B. a feed nozzle communicating with said mold, and

C. means for changing the effective length of said mold.

45. A mold assembly as in claim 44 wherein said means comprises means for moving said mold back and forth upon said feed nozzle.

46. A mold assembly according to claim 45 wherein said mold is rotatable about said feed nozzle.

47. A mold assembly according to claim 46 further including a bearing block affixed to said mold said bearing block being adapted to rotate about said feed nozzle; and means for rotating said mold and bearing block about said feed nozzle.

48. A mold assembly as in claim 47 wherein said means for rotating the mold and bearing block include: a drive sprocket which is allixed to said bearing block; and wherein said means for moving the mold back and forth upon said feed nozzle includes a groove in said bearing block and cam followers engaging said groove, said cam followers being free to rotate so that the mold may be moved back and forth while the mold is rotating about said feed nozzle.

49. A mold assembly according to claim 48 further including a mold ring which engages, and is rotatable with, said mold.

50. An apparatus as in claim 14 further including means for removing said first cooling medium from said casting.

51. An apparatus as in claim 50 wherein said means for removing said first cooling medium comprises: at least one rubber wiper adapted to contact the periphery of the casting,

said wiper being held in position by at least one holder, means for supporting said holder so that said wiper can engage the periphery of said casting.

52. An apparatus according to claim 51 in which a plurality of wipers are provided.

53. An apparatus as in claim 51 further including a concentric tube having a plurality of orifices and means for introducing a gas under pressure into said tube whereby said gas exits from said orifices to remove said first cooling medium not removed by said wiper.

54. An apparatus according to claim 53 in which the orifices are at an angle of 30 to 60 with respect to a plane passing through said concentric tube.

55. An apparatus as in claim 51 further including means for applying a second cooling medium to said casting.

56. An apparatus as in claim 55 wherein said means for applying said second cooling medium to said casting comprises: a header; means for introducing a cooling medium into said header; said header having a plurality of openings therein for applying said second cooling medium to said casting.

57. An apparatus as in claim 56 wherein said openings are at an angle of 15 to 45 with respect to the surface of the castmg.

58. An apparatus as in claim 55 further including means for removing said second cooling medium from said casting.

59. An apparatus as in claim 58 wherein said means for removing said second cooling medium comprises at least one rubber wiper contacting the periphery of said casting, said wiper being held in position by at least one holder; and means for supporting said holder so that said wiper can engage the periphery of said casting. 

1. A horizontal casting feed nozzle adapted to be used in conjunction with a horizontal casting mold utilized in making a continuous casting comprising: a nozzle body having a step therein; a capillary communicating with said step for carrying a lubricant thereto; a tip attached to the end portion of said nozzle body, said tip being nonwetting to molten aluminum; means for introducing a lubricant to flow through said capillary; and means for communicating with said step for regulating the amount of lubricant which passes over said tip to lubricate the casting.
 2. A feed nozzle according to claim 1 in which the means for regulating the flow of lubricant over said tip is a layer of fibrous material.
 3. A feed nozzle according to claim 2 in which the fibrous material is selected from the group consisting of felt, cotton yarn, Teflon, rayon and nylon.
 4. A feed nozzle according to claim 2 in which the fibrous material is a plurality of short, chopped fibers and said fibers being substantially perpendicular to the surface of said nozzle body.
 5. A feed nozzle according to claim 1 in which said tip completely covers the end portion of said nozzle body.
 6. A feed nozzle according to claim 1 in which means for sealing said feed nozzle with respect to said mold are provided which insure that said lubricant will pass over said tip.
 7. A feed nozzle according to claim 1 in which said capillary lies within said nozzle bOdy.
 8. A casting mold utilized in making a continuous casting comprising: a member having a concave outer surface and having an opening of constant diameter therethrough defining an inner surface; said member further having a plurality of helical grooves extending along the inner surface thereof for passage of a lubricant through said grooves to lubricate said casting.
 9. A mold according to claim 8 which is made of a material selected from the group consisting of deoxidized copper, aluminum and aluminum alloys, copper having a graphite insert, and deoxidized copper containing up to 1.3 percent chromium.
 10. A mold according to claim 9 which is made of deoxidized copper containing up to 1.3 percent chromium.
 11. A mold according to claim 10 in which the chromium content is about 0.8 percent.
 12. A mold according to claim 8 in which the grooves are from 0.001 to 0.003 inch deep.
 13. A mold according to claim 8 in which the concave mold surface is parabolic.
 14. An apparatus utilized in making a continuous casting comprising: A. a mold assembly, including a mold wherein at least a portion of the outer surface of said mold is concave and having an opening of constant diameter therethrough defining an inner surface, wherein said concave surface is contiguous with the end of said opening from which said casting emerges and wherein the diameter of said concave surface increases from said end portion, and a plurality of helical grooves extending along the inner surface of said mold for passage of a lubricant to lubricate said casting; a feed nozzle communicating with said mold, said mold being rotatable about said feed nozzle, and B. means for applying a first cooling medium to the outer surface of said mold and the emergent portion of said casting.
 15. An apparatus according to claim 14 in which the means for applying a cooling medium to said mold is fixed.
 16. An apparatus according to claim 14 in which the means for applying a cooling medium comprises a spray box having a circumferential baffle, said baffle having a plurality of openings therein.
 17. An apparatus according to claim 14 in which said spray box is provided with a plate affixed to said spray box, said plate being so shaped as to regulate the direction and pressure of applied cooling medium.
 18. An apparatus according to claim 17 in which said plate has a portion of reduced thickness which regulates said cooling medium.
 19. An apparatus according to claim 17 in which said spray box contains a circumferential header in addition to said baffle.
 20. An apparatus according to claim 17 in which said mold assembly includes a rotatable mold ring affixed to said mold and in which said mold ring engages a cam follower which is affixed to said spray box.
 21. A casting machine utilized in making a continuous casting comprising: means for holding a body of molten metal which defines a head of molten metal at least in excess of the diameter of said mold; a feed nozzle connected to the means for holding said body of molten metal; means for supporting said feed nozzle, said feed nozzle having a nozzle body having a step therein, a capillary communicating with said step for carrying a lubricant, a tip attached to the end portion of said nozzle body, means for introducing a lubricant to flow through said capillary, and means communicating with said step for regulating the amount of lubricant which passes over said tip to lubricate the casting; a mold assembly rotatable about said feed nozzle said mold assembly including a mold for horizontal casting; means for moving the mold assembly back and forth upon said feed nozzle; means for forcing said lubricant through said feed nozzle to lubricate said casting formed within said mold; means for applying a cooling medium to said mold; means for withdrawing said casting as it emerges from said mold and for supporting said casting while it solidifies.
 22. An apparatus according to claim 21 including means for removing the cooling medium from said casting.
 23. An apparatus according to claim 22 in which means are provided for applying additional cooling to he casting after said casting emerges from said mold.
 24. An apparatus according to claim 22 in which said means for withdrawing includes means for applying a force to the upper surface of said casting to hold said casting in engagement with said withdrawal mechanism.
 25. An apparatus according to claim 21 in which a part of the same rotational energy used to operate said means for withdrawing a casting is used to rotate the mold assembly.
 26. An apparatus utilized in making a continuous casting comprising: A. a mold having a concave outer surface and having an opening of constant diameter therethrough defining an inner surface said mold further having a plurality of helical grooves extending along the inner surface thereof for passage of a lubricant through said grooves to lubricate said casting; and B. A withdrawal mechanism for withdrawing said casting comprising: an endless chain made up of a plurality of feet, each of said feet having a carrying member having a concave surface upon which said casting is carried, said carrying member having means for moving along the base having a flat surface; and means for moving said endless chain into engagement with said casting and out of engagement with said casting after said casting has been moved away from said casting mold.
 27. An apparatus according to claim 26 including means associated with the base for guiding said chain as it moves along said base.
 28. An apparatus according to claim 26 in which said means for moving along said base are wheels.
 29. An apparatus according to claim 26 in which means are provided for exerting a force on the top of said casting to hold said casting in engagement with said carrier member.
 30. An apparatus according to claim 29 in which means are provided for varying the pressure applied to the casting.
 31. An apparatus according to claim 29 in which said force is applied to said casting through the use of a pneumatic cylinder or hydraulic cylinder.
 32. An apparatus according to claim 26 in which the means for urging said endless chain into engagement with said casting comprises at least one drive sprocket wheel.
 33. An apparatus according to claim 32 in which an idler wheel is provided which said endless chain engages in its travel.
 34. An apparatus according to claim 32 in which said drive wheel has openings therein and wherein said endless chain engages said openings as said endless chain travels about said wheel.
 35. An apparatus according to claim 32 in which the source of power used for moving said endless chain is a motor.
 36. An apparatus according to claim 35 in which a part of the rotational energy obtained from said motor is used to rotate the mold.
 37. An apparatus according to claim 35 in which at least a part of the rotational energy obtained from said motor is used to drive a sprocket wheel which drives said endless chain.
 38. An apparatus according to claim 26 in which means for testing the soundness of said casting is provided after said casting is moved away from the mold.
 39. An apparatus according to claim 38 in which the testing means used is ultrasonic testing.
 40. A mold according to claim 8 in which a mold coolant exits from said externally concave outer surface at an angle of 3* to 20* to the surface of the casting.
 41. A mold according to claim 40 in which the angle is 3* to 10*.
 42. An apparatus according to claim 21 wherein at least a portion of the outer surface of said mold is concave and having an opening of constant diameter therethrough, wherein said concave surface is contiguous with the end of said opening from which said casting emerges and wherein the diameter of said concave surface increases from said end portion, and wHerein said mold has a plurality of helical grooves extending along the inner surface thereof for passage of a lubricant through said grooves to lubricate said casting and further wherein said cooling medium exits from said concave surface at an angle of from 3* to 20* to the surface of said casting.
 43. An apparatus according to claim 42 in which the angle is 3* to 10* to the surface of the casting.
 44. A mold assembly for a continuous casting machine for making a continuous casting comprising: A. a mold having a concave outer surface and having an opening of constant diameter therethrough defining an inner surface; said mold further having a plurality of helical grooves extending along the inner surface thereof for passage of lubricant through said grooves to lubricate said casting, B. a feed nozzle communicating with said mold, and C. means for changing the effective length of said mold.
 45. A mold assembly as in claim 44 wherein said means comprises means for moving said mold back and forth upon said feed nozzle.
 46. A mold assembly according to claim 45 wherein said mold is rotatable about said feed nozzle.
 47. A mold assembly according to claim 46 further including a bearing block affixed to said mold said bearing block being adapted to rotate about said feed nozzle; and means for rotating said mold and bearing block about said feed nozzle.
 48. A mold assembly as in claim 47 wherein said means for rotating the mold and bearing block include: a drive sprocket which is affixed to said bearing block; and wherein said means for moving the mold back and forth upon said feed nozzle includes a groove in said bearing block and cam followers engaging said groove, said cam followers being free to rotate so that the mold may be moved back and forth while the mold is rotating about said feed nozzle.
 49. A mold assembly according to claim 48 further including a mold ring which engages, and is rotatable with, said mold.
 50. An apparatus as in claim 14 further including means for removing said first cooling medium from said casting.
 51. An apparatus as in claim 50 wherein said means for removing said first cooling medium comprises: at least one rubber wiper adapted to contact the periphery of the casting, said wiper being held in position by at least one holder, means for supporting said holder so that said wiper can engage the periphery of said casting.
 52. An apparatus according to claim 51 in which a plurality of wipers are provided.
 53. An apparatus as in claim 51 further including a concentric tube having a plurality of orifices and means for introducing a gas under pressure into said tube whereby said gas exits from said orifices to remove said first cooling medium not removed by said wiper.
 54. An apparatus according to claim 53 in which the orifices are at an angle of 30* to 60* with respect to a plane passing through said concentric tube.
 55. An apparatus as in claim 51 further including means for applying a second cooling medium to said casting.
 56. An apparatus as in claim 55 wherein said means for applying said second cooling medium to said casting comprises: a header; means for introducing a cooling medium into said header; said header having a plurality of openings therein for applying said second cooling medium to said casting.
 57. An apparatus as in claim 56 wherein said openings are at an angle of 15* to 45* with respect to the surface of the casting.
 58. An apparatus as in claim 55 further including means for removing said second cooling medium from said casting.
 59. An apparatus as in claim 58 wherein said means for removing said second cooling medium comprises at least one rubber wiper contacting the periphery of said casting, said wiper being held in position by at least one holder; and means for supporting said holder so that said wiper can engage the periphery of said casting. 